®
AIRLESS PAINT LINE STRIPER
SERVICE/OPERATION
MANUAL
SURE STRIPE
3650 & 4050
FIELD STRIPE
MODEL D & PLUS
001-822 SEPT 08
1
TABLE OF CONTENTS
SECTION FIGURE
Introduction...................................................... 1
Safety Warnings .............................................. 2
Setting Up........................................................ 5
Flushing........................................................... 5
How to Flush ................................................... 6
Starting Up ...................................................... 7
Pressure Relief Procedure .............................. 8
Daily Maintenence........................................... 8
Line Striping Operation.................................... 9
Airless Spray Gun Operation......................... 10
Airless Spray gun Assembly...........................11
Airless Spray Gun Troubleshooting............... 12
Rev Tips ........................................................ 13
Field Troubleshooting.................................... 13
Servicing Fluid Pump .................................... 14
Servicing Outlet Valve ................................... 15
Servicing Inlet Valve ...................................... 15
Packing Replacement Procedures ................ 16
Gearbox Assembly ........................................ 18
Clutch Assembly............................................ 19
Frame Assembly............................................ 20
Swivel Wheel Assembly ................................ 21
Gun Assembly ............................................... 22
Gun Holder Assembly.................................... 22
Paint System ................................................. 23
Suction Assembly.......................................... 24
Floating Gun Assembly ................................. 25
Replacement of Electrical Control Board ...... 26
Pressure Calibration on the Control Board.... 26
Clutch Troubleshooting.................................. 27
Notes ............................................................. 28
Striping Accessories...................................... 29
Airlessco Accessories.................................... 30
1 Filling the Packing Nut/Wet Cup................ 5
2. Spray Tip ................................................... 6
3. Prime Valve ............................................... 6
4. Pressure Control Knob .............................. 6
5. Choke, Fuel Throttle.................................. 6
6. Static Discharge ........................................ 6
7. Gun Safety Latch..................................... 10
8. Major Gun Components .......................... 10
9. Spray Tip ................................................. 10
10. Spray Tip Assembly ................................. 10
11. Airless Spray Gun Assembly.....................11
12. Fluid Pump .............................................. 14
13. Outlet Valve ............................................. 15
14. Inlet Valve ................................................ 15
15. Packing.................................................... 16
16. Packing Cutaway..................................... 17
17. Gearbox Assembly .................................. 18
18. Clutch Assy.............................................. 19
19. Frame Assembly...................................... 20
20. Swivel Wheel Assembly .......................... 21
21. Gun Assembly ......................................... 22
22. Gun Holder Assembly.............................. 22
23. Paint System ........................................... 23
24. Suction Assembly.................................... 24
25. Floating Gun Assembly ........................... 25
26. Control Board .......................................... 26
2
INTRODUCTION
The Sure Stripe 3650 and Sure Stripe 4050, as well as
their respective Field Stripe versions, the Field Stripe
Model D and Field Stripe Plus (+) have been designed to
produce profesional results at very reasonable prices.
Using our proven LP airless piston-powered paint pump,
with triple life externally adjustable packing system and
quality, clutch based, electronic pressure control system,
the Sure Strip and Field Stripe stripers can be relied upon
to get the job done for years to come.
Field Stripe units are equipped with a wheeled gun arm to
ensure consistant lines on athletic elds.
All four units can also be used as mobile airless paint
sprayers.
Part No. 305-401 305-402 305-405 305-406
Max Pressure 3000 PSI 3000 PSI 3000 PSI 3000 PSI
Output (At Pressure) 0.70 GPM 0.80 GPM 0.70 GPM 0.80 GPM
Tip Size 1 Gun 0.027 in. 0.029 in. 0.027 in. 0.029 in.
Motor Duro 4HP
Weight 166 lbs 166 lbs 171lbs 171 lbs
HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY
SERIOUS INJURY. OBSERVE ALL WARNINGS!
MANUAL NOTATIONS
WARNING - Alerts user to avoid or correct conditions that
could cause bodily injury.
CAUTION - Alerts user to avoid or correct conditions that
could cause damage to or destruction of equipment.
IMPORTANT - Alerts users to steps or procedures that are
essential to proper equipment repair and maintenance.
NOTE - Identies essential procedures or extra information.
SS3650 SS4050 FS Model D FS Plus
Honda GX160
BEFORE OPERATING THIS UNIT, READ AND FOLLOW
ALL SAFETY WARNINGS AND INSTRUCTIONS RELATED
TO THE USAGE OF THIS EQUIPMENT ON PAGES 2, 3 & 4.
READ, LEARN, AND FOLLOW THE PRESSURE RELIEF
PROCEDURE ON PAGE 8 OF THIS MANUAL.
Duro 4hp
Honda GX160
All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.
NO MODIFICATIONS or alterations of any AIRLESSCO Equipment or part is allowed.
1
3
WARNINGS
MEDICAL ALERT - Airless Spray Wounds
If any uid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE
CUT. Tell the doctor exactly what uid was injected. Have
him read the following "NOTE TO PHYSICIAN".
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. OBSERVE ALL
WARNINGS. THIS SPRAYER IS FOR PROFESSIONAL USE ONLY.
INJECTION HAZARD
FLUIDS UNDER HIGH PRESSURE FROM SPRAY OR
LEAKS CAN PENETRATE THE SKIN AND CAUSE
EXTREMELY SERIOUS INJURY, INCLUDING THE
NEED FOR AMPUTATION.
NEVER point the spray gun towards anyone or at any part
of the body.
NEVER put hand or ngers over the spray tip. Do not use
rag or other materials over your ngers. Paint will penetrate
through material and into the hand.
NEVER try to stop or deect leaks with your hand or body.
ALWAYS have gun tip guard in place when spraying.
ALWAYS lock gun trigger when you stop spraying.
ALWAYS remove tip from the gun to clean it.
NEVER try to "blow back" paint, it’s not an air sprayer.
ALWAYS follow the PRESSURE RELIEF PROCEDURE,
as shown on page 8, before cleaning or removing the spray
tip or servicing any system equipment.
Be sure equipment safety devices are operating properly
before each use.
ALWAYS tighten all uid connections before each use.
MEDICAL TREATMENT
If any uid appears to penetrate your skin, get
EMERGENCY CARE AT ONCE.
DO NOT TREAT AS A SIMPLE CUT.
• Go to an emergency room immediately.
• Tell the doctor you suspect an injection injury.
• Tell him what kind of material you were spraying with and
have him read NOTE TO PHYSICIAN above.
GENERAL PRECAUTION
NEVER alter equipment in any manner.
NEVER smoke while in spraying area.
NEVER spray highly ammable materials.
NEVER use around children.
NEVER allow another person to use sprayer unless he is
thoroughly instructed on its' safe use and given this
operators manual to read.
ALWAYS wear a spray mask, gloves and protective eye
wear while spraying.
ALWAYS ensure re extinquishing equipment is readily
available and properly maintained.
NEVER LEAVE SPRAYER UNATTENDED WITH
PRESSURE IN THE SYSTEM. FOLLOW PRESSURE
RELIEF PROCEDURES ON PAGE 8.
2
NOTE TO PHYSICIAN: Injection in the skin is a traumatic
injury. It is important to treat the injury surgically as soon as
possible. DO NOT DELAY treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable.
ALWAYS INSPECT SPRAYING AREA
Keep spraying area free from obstructions.
Make sure area has good ventilation to safely remove
vapors. NEVER keep ammable material in spraying area.
NEVER spray in vicinity of open ame or other sources of
ignition. Spraying area must be at least 20 ft. away from
spray unit.
SPRAY GUN SAFETY
ALWAYS set safety lock on the gun in "LOCKED" position
when not in use and before servicing or cleaning.
DO NOT remove or modify any part of gun.
ALWAYS remove spray tip when cleaning.
Flush unit with LOWEST POSSIBLE PRESSURE.
CHECK operation of all gun safety devices before each
use. Be very careful when removing the spray tip or hose
from gun. A plugged line contains uid under pressure. If
the tip or line is plugged, follow the PRESSURE RELIEF
PROCEDURE as outlined on page 8.TIP GUARD
TIP GUARD
ALWAYS have the tip guard in place on the spray gun
while spraying. The tip guard alerts you to the injection
hazard and helps prevent accidentally placing your ngers
or any part of your body close to the spray tip.
SPRAY TIP SAFETY
USE EXTREME CAUTION when cleaning or changing
spray tips. If the spray tip clogs while spraying, engage the
gun safety latch immediately.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
before removing the spray tip to clean it.
NEVER wipe off build up around the spray tip.
ALWAYS remove tip & tip guard to clean AFTER pump
is turned off and the pressure is relieved by following the
PRESSURE RELIEF PROCEDURE.
WARNINGS CONTINUED ON NEXT PAGE.........
WARNINGS - CONTINUED
ALWAYS INSPECT SPRAYING AREA
Keep clear of moving parts when starting or operating
the sprayer. Do not put your ngers into any openings
to avoid amputation by moving parts or burns on hot
parts.Precaution is the best insurance against an
accident.
When starting the engine, maintain a safe distance
from moving parts of the equipment.
Before adjusting or servicing any mechanical part
of the sprayer, follow the PRESSURE RELIEF
PROCEDURE on page 8, and remove the ignition
cable from the spark plug to prevent accidental
starting of sprayer.
HOSES
Tighten all uid connections securely before each use. High
pressure uid can dislodge a loose coupling or allow high
pressure spray to be emitted from the coupling and result in
an injection injury or serious bodily injury.
Use only hose that has a spring guard. The spring guard
helps protect the hose from kinks or other damage which
could result in hose rupture and cause an injection injury.
GROUNDING
Ground the sprayer and other components in the system
to reduce the risk of static sparking, re or explosion which
can result in serious bodily injury and property damage.
ALWAYS GROUND ALL OF THESE COMPONENTS:
1. Sprayer: Connect a ground wire and clamp (supplied) to
a true earth ground.
2. Fluid Hose: use only grounded hoses.
3. Spray gun or dispensing valve: grounding is obtained
through connection to a properly grounded uid hose
and pump.
4. Object being sprayed: according to your local code.
5. All solvent pails used when ushing should only be
metal pails which are conductive.
Once each week, check electrical resistance of hose (when
using multiple hose assemblies, check overall resistance of
unpressurized hose must not exceed 29 megohms (max)
for any coupled length or combination of hose lengths. If
hose exceeds these limits, replace it immediately.
Never exceed 500 Ft. (150 m.) overall combined hose
length to assure electrical continuity.
NEVER use a damaged hose, which can result in hose
failure or rupture and cause in injection injury or other
serious bodily injury or bodily damage. Before each use,
check entire hose for cuts, leaks, abrasion or bulging of
cover, or damage or movement of couplings. If any of
these conditions exist, replace the hose immediately.
Never use tape or any device to try to mend the hose as it
cannot contain the high pressure uid. NEVER ATTEMPT
TO RECOUPLE THE HOSE. High pressure hose is not
recoupleable.
Help prevent damage to the hose by handling and routing
it carefully. Do not move the sprayer by pulling it with the
hose.
LABELING
Keep all labels on the unit clean and readable.
Replacement labels are available from manufacturer.
TOXIC FLUID HAZARD
Hazardous uid or toxic fumes can cause serious injury or
death if splashed in eyes or on skin, inhaled or swallowed.
Know the hazards of the uid you are using. Store &
dispose of hazardous uids according to manufacturer,
local, state & national guidelines.
ALWAYS wear protective eyewear, gloves, clothing
and respirator as recommended by uid manufacturer.
WARNINGS CONTINUED ON NEXT PAGE.........
3
5
WARNINGS - CONTINUED
AVOID COMPONENT RUPTURE
This sprayer operates at 3000 psi (205 bar). ALWAYS be
sure that all components and accessories have a maximum
working pressure of at least 3000 psi to avoid rupture
which can result in serious bodily injury including injection
and property damage.
NEVER leave a pressurized sprayer unattended to avoid
accidental operation of it which could result in serious
bodily injury.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
whenever you stop spraying and before adjusting,
removing or repairing any part of the sprayer.
NEVER alter or modify any part of the equipment to avoid
possible component rupture which could result in serious
bodily injury and property damage.
NEVER use weak or damaged or non-conductive paint
hose. Do not allow kinking or crushing of hoses or allow it
to vibrate against rough or sharp or hot surfaces. Before
each use, check hoses for damage and wear and ensure
all uid connections are secure.
REPLACE any damaged hose. NEVER use tape or any
device to mend the hose.
NEVER attempt to stop any leakage in the line or ttings
with your hand or any part of the body. Turn off the unit
and release pressure by following PRESSURE RELIEF
PROCEDURE.
ALWAYS use approved high pressure ttings and
replacement parts.
ALWAYS ensure re extinquishing equipment is readily
available and properly maintained.
PREVENT STATIC SPARKED FIRE/ EXPLOSIONS
ALWAYS be sure all equipment and objects being sprayed
are properly grounded. ALWAYS ground sprayer, paint
bucket and object being sprayed. See "grounding" on page
3 for detailed grounding information.
Vapors created when spraying can be ignited by sparks.
To reduce the risk of re, always locate the sprayer at least
20 feet (6 m.) away from the spray area. DO NOT plug in
or unplug any electrical cords in the spray area, which can
create sparks, when there is any chance of igniting vapors
still in the air. Follow the coating & solvent manufacturers
safety warnings and precautions.
Use only conductive uid hoses for airless applications. Be
sure gun is grounded through hose connections. Check
ground continuity in hose & equipment. Overall (end to
end) resistance of unpressurized hose must not exceed 29
megohms for any coupled length or combination of hose
length. Use only high pressure airless hoses with static
wire approved for 3000 psi.
FLUSHING
Reduce the risk of injection injury, static sparking or
splashing by following the specic cleaning procedure on
page 6 and 8.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
on page 8.
ALWAYS remove the spray tip before ushing. Hold a
metal part of the gun rmly to the side of a metal pail and
use the lowest possible uid pressure during ushing.
NEVER use cleaning solvents with ash points below 140
degress F. Some of these are: acetone, benzene, ether,
gasoline, naphtha. Consult your supplier to be sure.
NEVER SMOKE IN THE SPRAYING/CLEANING AREA.
WARNING
Do not use halogenated solvents in this system. The prime
valve, 2 gun manifold and most airless guns have aluminum
parts and may explode. Cleaning agents, coatings, paints or
adhesives may contain halogenated hydrocarbon solvents.
DON"T TAKE CHANCES! Consult your material suppliers to
be sure. Some of the most common of these solvents are:
Carbontetrachloride, Chlorobenzene, Dichloroethane, Dichloroethyl Ether, Ethylbromide, Ethylchloride, Tethrachloethane.
Alternate valves and guns are available if you need to use
these solvents.
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR THINNERS:
1. When spraying with ammable liquids, the unit must be located a minimum of 25 feet away from the spraying area in
a well ventilated area. Ventilation must be sufcient enough to prevent the accumulation of vapors.
2. To eliminate electrostatic discharge, ground the spray unit, paint bucket and spraying object. Use only high
pressure airless hoses approved for 3000 psi which is conductive.
3. Remove spray tip before cleaning gun and hose. Make contact of gun with bucket and spray without the tip in a well
ventilated area, into the grounded steel bucket.
4. Never use high pressure in the cleaning process. USE MINIMUM PRESSURE.
5. Do not smoke in spraying/cleaning area.
4
GAS ENGINE PRECAUTIONS
Place unit 25 feet away from spraying in ventilated area.
NEVER operate in buildings unless exhaust is piped outside.
NEVER allow hose to lay against engine mufers or hot parts.
NEVER rell fuel tank while engine is hot or is running.
IMPORTANT: United States Government safety standards
have been adopted under the Occupational Safety & Health
Act. These standards, particularly the General Standards,
Part 1910, & the Construction Standards, part 1926 should
be consulted.
SETTING UP
1. CONNECT THE HOSE AND GUN
a. Remove the plastic cap plug from the outlet and screw a
conductive or grounded 3000 psi spray hose onto
uid outlet.
b. Connect an airless spray gun to the other end of the
hose, but do not install the spray tip yet!
NOTE: Do not use thread sealer on swivel unions as they
are made to self seal.
NOTE: The 6' whip hose should always be 3/8".
2. FILL THE PACKING NUT/WET CUP
Fill the Packing Nut/Wet Cup 1/3 full with Airlessco Throat
Seal Oil (TSO). FIG 1 BELOW.
FIG. 1
3. CHECK THE ENGINE OIL LEVEL
a. Unscrew the oil ll plug. The dipstick is attached to
the plug.
b. Without threading the plug into place, check to be sure
the oil is up to the top mark on the dipstick.
c. If oil is needed, refer to engine manual.
4. FILL THE FUEL TANK
WARNING: Fuel spilled on a hot surface can cause a re or
explosion and cause serious bodily injury and property damage. Always shut off the engine and let it cool before lling
the tank, and carefully follow steps a - c below being sure not
to spill any fuel.
a. Close the fuel shutoff valve.
b. Use only clean, fresh, well-known brands of unleaded
regular grade gasoline.
c. Remove the fuel cap and ll tank. Be sure the air vent
in the ll cap is not plugged so fuel can ow to the
carburetor, then replace the cap.
5. FLUSH THE SPRAYER
a. Flush sprayer per instructions below.
FLUSHING
1. NEW SPRAYER 5. STORAGE
Your unit was factory tested in an anti-freeze solution which
was left in the pump. Before using oil-base paint, ush with
mineral spirits only.
Before using water-base paint ush with mineral spirits,
followed by soapy water, then a clean water ush.
2. CHANGING COLORS
Flush with a compatible solvent such as mineral spirits or
water.
3. CHANGING FROM WATER-BASE TO
OIL-BASE PAINT
Flush with soapy water, then mineral spirits.
4. CHANGING FROM OIL-BASE TO
WATER-BASE PAINT
Flush with mineral spirits, followed by soapy water, then a
clean water ush.
Oil-base paint: Flush with mineral spirits.
Water-base paint: Flush with water, then mineral spirits and
leave the pump, hose and gun lled with mineral spirits.
For longer storage, use mixture of mineral spirits and motor
oil (half & half). Shut off the sprayer, follow PRESSURE
RELIEF PROCEDURE on page 8 to relieve pressure and
make sure prime valve is left open.
6. START UP AFTER STORAGE
Before using water-base paint, ush with soapy water and
then a clean water ush.
When using oil-base paint, ush out the mineral spirits with
the material to be sprayed.
5
7
HOW TO FLUSH
1. Be sure the gun safety latch is engaged and there
is no spray tip in the gun. Refer to Fig. 2. Refer to your
separate instruction manual provided with your gun on its
safety features and how to engage safety latch.
2. Pour enough clean, compatible solvent into a large,
empty metal pail to ll the pump and hoses.
3. Place the suction tube into the pail or place the pail
under the pump.
4. Turn pressure control knob to low. Refer to Fig. 4.
5. Open the prime valve to the open - "Priming Position".
This will allow an easy start. Refer to Fig. 3.
6. Turn the engine ON/OFF switch to ON.
7. Move the choke toward the closed position as per Fig.5.
8. Move the throttle lever slightly to the left as per Fig.5.
9. Turn the fuel valve ON as per Fig. 5. Pull the start rope.
Pull the engine over against compression stroke and
then let the rope rewind slowly into the starter. Pull
rmly and rapidly to start the engine. Do NOT drop the
rope. Hold on to the handle while rewinding, or the rope
may rewind improperly and jam the assembly. If the
engine does not start, open the choke a little more. If the
engine oods, open the choke all the way and continue
cranking.
10. After the engine is warm, gradually close the choke,
raise the RPM of engine slightly by moving throttle to the
left. Close the prime valve. Refer to Fig. 3
11. Point the gun into the metal pail and hold a metal part of
the gun rmly against the pail Refer to g. 6.
12. Disengage the gun safety latch and squeeze the gun
trigger. At the same time, slowly turn the pressure
control knob clockwise just enough to move liquid at low
pressure.
13. Allow the pump to operate until clean solvent comes
from the gun.
14. Release the trigger and engage the gun safety latch.
15. If you are going to start spraying, place the pump or
suction tube into the supply container. Release the
gun safety latch and trigger the gun into another empty,
metal container, holding a metal part of the gun rmly
against the metal pail (Fig. 6), forcing the solvent from
the pump and hose. When paint starts coming from gun,
turn pressure control knob to minimum pressure, place
prime valve in prime (open) position and engage the gun
safety latch.
16. If you are going to store the sprayer, remove the suction
tube or pump from the solvent pail force the solvent from
the pump and hose. Engage the gun safety latch and
refer to the "Storage" Procedure on page 5. Step 5.
17. Whenever you shut off the sprayer follow the
PRESSURE RELIEF PROCEDURE warning on page 8.
FIG. 2
REMOVE SPRAY TIP. ENGAGE
GUN SAFETY LATCH.
FIG. 4
PRESSURE CONTROL KNOB
FIG. 5
CHOKE LEVER
FUEL VALVE
FIG. 6
MAINTAIN FIRM
METAL TO METAL
CONTACT BETWEEN GUN AND
CONTAINER
FIG. 3
PRIME VALVE
CLOSED
(Pressure)
OPEN
(Priming &
Pressure Relief
HIGH
PRESSURE
THROTTLE LEVER
WARNING: To reduce the risk of static sparking, which
can cause re or explosion, always hold a metal part of
the gun rmly against the metal pail when ushing. This
also reduces splashing. Refer to Fig 6.
6
STARTING UP
1. LEARN THE FUNCTIONS OF THE
CONTROLS.
PRIME/PRESSURE (PR) RELIEF VALVE is used to
prime pump and to relieve pressure from gun, hose and tip.
(Prime/PR Valve) Used to relieve pressure
from gun, hose & tip and to primethe unit
when in OPEN position. (It is in open
positionwhen there is a wider gap between
valve handle and cam body.)
When in CLOSED position,there is only
a very slight gap between handle & body.
When closed the system is pressurized.
Handle as a loaded rearm!
PRESSURE CONTROL KNOB is used to
adjust pressure. Turn clockwise (CW) to
increase pressure and counterclockwise
(CCW) to decrease pressure.
2. PREPARE THE MATERIAL
a. Prepare the material according to the material
manufacturer's recommendations.
b. Place the suction tube into the material container.
c. If more coverage is needed, use a larger tip rather than
increasing the pressure.
d. Check the spray pattern. The tip size and angle
determines the pattern width and ow rate.
FOLLOW THE "PRESSURE RELIEF PROCEDURE".
To reduce the risk of injection, never hold your hand, body,
ngers or hand in a rag in front of the spray tip when cleaning
or checking for a cleared tip. Always point the gun toward the
ground or into a waste container when checking to see if the
tip is cleared or when using a self-cleaning tip.
When you spray into the paint bucket, always use the
lowest spray pressure and maintain rm metal to metal contact
between gun and container.
To stop the unit in an emergency, turn the engine off. Then
relieve the uid pressure in the pump and hose as instructed
in the Pressure Relief Procedure.
5. WHEN SHUTTING OFF THE SPRAYER
3. STARTING THE SPRAYER
a. Prime/PR Valve must be "OPEN" in the priming
position.
b. When you have ensured that the gun safety latch is
engaged, attach tip and safety guard.
c. Turn the engine ON/OFF switch to the "ON"
position. Pull rope vigorously until engine starts.
d. Turn Pressure Control Knob clockwise to prime the
pump.
e. After the pump is primed, turn Prime/PR Valve to the
"Closed" position.
f. Turn Pressure Control Knob to the desired spray
pressure.
g. Disengage the gun safety latch and you are ready to
spray.
4. ADJUSTING THE PRESSURE
a. Turn the Pressure Control Knob Clockwise to increase
pressure and counterclockwise to decrease pressure.
b. Always use the lowest pressure necessary to completely
atomize the material.
NOTE: OPERATING THE SPRAYER AT HIGHER
PRESSURE THAN NEEDED, WASTES MATERIAL,
CAUSES EARLY TIP WEAR, AND SHORTENS
SPRAYER LIFE.
a. Whenever you stop spraying, even for a short break,
follow the "Pressure Relief Procedure".
b. Clean the tip & gun as recommended in the seperate
Gun Manual supplied with the gun.
c. Flush the sprayer at the end of each work day, if the
material you are spraying is water-based, or if it could
harden in the sprayer overnight. See "Flushing". Use a
compatible solvent to ush, then ll the pump and hoses
with an oil based solvent such as mineral spirits.
d. For long term shutdown or storage, refer to the
"Flushing" section of this manual.
Be sure to relieve pressure in the pump after lling with
Airlessco Pump Conditioner.
AVOIDING TIP CLOGS
There is an easy way to keep the outside of the tip clean from
material build up:
Every time you stop spraying, for even a minute, lock the gun
and submerge it into a small bucket of thinner suitable for the
material sprayed.
Thinner will dissolve the buildup of paint on the outside of tip,
tip guard and gun much more effectively if the paint doesn't
have time to dry out completely.
7
9
PRESSURE RELIEF PROCEDURE
IMPORTANT!
TO AVOID POSSIBLE SERIOUS BODY INJURY, ALWAYS FOLLOW THIS PROCEDURE WHENEVER THE
SPRAYER IS SHUT OFF, WHEN CHECKING IT, WHEN INSTALLING, CHANGING OR CLEANING TIPS,
WHENEVER YOU STOP SPRAYING, OR WHEN YOU ARE INSTRUCTED TO RELIEVE THE PRESSURE.
1. Engage the gun safety latch. Refer to the separate
instruction manual provided with your gun on its safety
features and how to engage safety latch.
2. Turn the unit off.
3. Disengage the gun safety latch and trigger the gun to
relieve residual uid pressure.
HOLD METAL PART OF THE GUN IN CONTACT WITH
GROUNDED METAL PAIL. USE MINIMUM PRESSURE !
4. Turn Prime/Pressure Relief Valve (PR
Valve) to the open (priming) position to
relieve residual uid pressure.
THERE WILL BE A WIDER GAP BETWEEN VALVE
HANDLE AND CAM BODY WHEN IN OPEN POSITION.
IN THE CLOSED POSITION THERE IS ONLY A VERY
SLIGHT GAP.
NOTE: THE VALVE HANDLE CAN MOVE BOTH
CLOCKWISE AND COUNTER CLOCKWISE AND CAN
FACE DIFFERENT DIRECTIONS.
5. Re-engage gun safety latch and close
Prime/Pressure Relief Valve.
If the SPRAY TIP OR HOSE IS CLOGGED, follow Step
1 through 5 above. Expect paint splashing into the bucket
while relieving pressure during Step 4.
DAILY MAINTENANCE
1. Always stop the pump at the bottom of its stroke when
you take a break or at the end of the day. This helps
keep material from drying on the rod, damaging
the packings.
2. Keep the displacement pump packing nut/wet cup 1/3
full of Airlessco Throat Seal Oil at all times. The TSO
helps protect the packings and rod.
3. Lubricate Connecting Rod Pin every 3 months.
4. Inspect the packing nut daily. Your paint pump has
Airlessco's patented "Triple Life Packing System".
Packing life will be extended a minimum of 3 times if the
proper packing tightening procedure is followed!
8
If you suspect that pressure hasn't been relieved due to
damaged Prime/Pressure Relief Valve or other reason,
engage the gun safety latch and take your unit to an
authorized Airlessco Service Center.
PACKING TIGHTENING PROCEDURE:
Inspect the packing nut daily!If seepage of paint into the
packing nut and/ or movement of the piston upward is
found (while not spraying), the packing nut should be
tightened enough to stop leakage only, but not any tighter.
OVERTIGHTENING WILL DAMAGE THE PACKINGS
and reduce the packing life to the life of other piston
pumps.
LINE STRIPING OPERATION
1. CHOOSE THE GUN ARM POSITION 5. ALIGN SWIVEL WHEEL ASSEMBLY
There is a hole in each corner of the striper frame, in which
the gun arm can be mounted. In a standard set up, the gun
arm would be mounted in the right hand near the single
wheel. This allows for an easier visual check for straight
line striping and for basic arc striping.
2. CHOOSE THE HANDLEBAR POSITIONS
Choose the handlebar position. The handlebars can be
adjusted by loosening the bolts (g. 19, item 10) and
rotating each handlebar to desired heights, then tightening
the bolts. Rotating the handlebars all the way forward
allows for easy storage of the unit.
3. SETTING UP THE GUNS
a. Ensure that a striping tip is in the gun.
b. Pick a tip size for the desired line width.
EXAMPLE: a 317ST tip for a four inch line.
c. Place gun into the gun holder, so that the top of the
taper on the gun handle is ush with the edge of the
gun holder.
d. Set gun height for the desired line width. Adjust height
by loosening the small black handle on the gun holder
assembly and slide the gun arm to the correct height.
Now tighten the handle. This will require some
experimentation to nd the correct height. It is suggested
that tape, or some other method is used to mark the
height of commonly used settings.
e. Attach the swivel heads to the gun if painting curbs
or wide stripes.
f. Angle the guns slightly forward. This allows the spray
pressure from the guns to help blow dirt and debris out of
the path of the new stripes.
4. CABLE TENSION ADJUSTMENT
Once the handle and gun arm assembly is set up to the
preferred position, pressurize the unit and trigger the gun to
ensure that it activates and releases correctly. If not, adjust
the cable tension as follows:
STRAIGHT LINES
a. Stripers are factory aligned, but if necessary, loosen the
two bolts (g. 20, item 19) on the swivel wheel assembly,
just enough to be able to move the wheel by hand. Align
wheel and re-tighten bolts.
b. Place the turnbuckle over the two mounting nubs on the
frame.
c. Pressurize the unit with water and Airlessco's Pump
Conditioner and spray out several lines with the swivel
assembly in the locked position. Use the turnbuckle to
ne tune the alignment of the wheels, until the stripes
are straight.
d. Tighten the jam nuts on the turnbuckle to afx the
turnbuckle length for future reference.
e. Tighten the ratchet handles.
CURVES AND ARCS
Basically the same as above, except the swivel wheel
assembly is set at angle. The swivel assembly can be
adjusted to 30 degrees either side of straight ahead. If
you have arcs that you paint regularly, purchase additional
turnbuckles (136-231) and keep them set to those arc
sizes.
6. MISCELLANEOUS OPPERATIONS
a. CURBS: Adjust gun to desired height and turn swivel
head towards curb.
b. WIDE STRIPES: Install wider fan striping tips and raise
the gun height to achieve the desired width line.
c. STENCILS: Install standard spray tip on the outer gun.
Remove this gun from the gun holder and spray out the
stencils. A second gun and hose can be attatched and
bolted with a ball valve for stencils.
d. STANDARD PAINTING: Same as stencils, but use
additional paint hose as required.
a. Locate the adjustment knobs on the base of the gun
trigger, where the cable connects to the gun trigger
assembly.
b. Loose the locking nut and move the adjusting screw until
the slack has been removed from the cable.
c. Tighten locking nut and retest gun triggers for proper
function.
NOTE: THERE IS AN ADDITIONAL CABLE
ADJUSTMENT WHERE THE CABLE ATTACHES TO
THE GUN HOLDER ASSEMBLY. USE ONLY IF THE
GUN TRIGGER ADJUSTMENT IS INSUFFICIENT.
9
11
AIRLESS SPRAY GUN OPERATION
SPRAY
Attach spray gun to airless unit and tighten ttings securely.
Set the gun safety latch. (Also may be called gun safety
FIG. 7
lock, or trigger lock)
* The gun safety latch should always be set when the gun
is not being triggered.
Read all warnings and safety precautions supplied with the
spray gun and in product manual.
MAJOR COMPONENTS OF SPRAY GUN AND REVERSIBLE SPRAY TIP
FIG. 8 FIG. 9
REVERSIBLE
SPRAY TIP
TIP GUARD
TRIGGER GUARD
GUN SAFETY
LATCH OR LOCK
HANDLE
(FILTER INSIDE)
SPRAY TIP ASSEMBLY CLEANING FILTER IN GUN HANDLE
1. Be sure pressure relief procedure is followed before
assembling tip and housing to the gun.
2. Lock gun safety latch.
3. Insert REV-TIP™ cylinder into the REV-GUARD™
(guard housing assembly).
4. Guide metal seat into REV-GUARD™ (guard housing
assembly) through retaining nut & turn until it seats
against the cylinder.
5. Insert O-Ring gasket on metal seat so it ts in the
grooves.
6. Finger tighten REV-GUARD™ retaining nut onto the gun.
7. Turn guard in the desired position.
8. Completely tighten the retaining nut.
To clean the lter, use a brush dipped in an appropriate
solvent. Change or clean lters at least once a day. Some
types of latex may require a lter change after four hours of
operation.
1. Lock gun safety latch.
2. Turn REV-TIP™ handle 180 degrees.
3. Disengage trigger lock & trigger gun into pail.
4. If the REV-TIP™ handle appears locked (resists
turning), loosen the retaining nut. The handle will now
turn easily.
5. Engage gun safety latch & return handle to the
spray position.
FIG. 10
RETAINING NUT
REV-GUARD™
GUARD HOUSING ASSEMBLY
G Thread 7/8" 561-002
F Thread 11/16" 561-001
REV-TIP™ CYLINDER
Part # 561-XXX
CLEANING SPRAY GUN
Immediately after the work is nished, ush the gun out
with a solvent. Brush pins with solvent and oil them lightly
so they will not collect dried paint.
10
O-RING GASKET
Part # 561-026
METAL SEAT
Part # 561-029
Should the spray tip become clogged, relieve pressure
from hose by following the "Pressure Relief Procedure."
Secure gun with the safety latch, take off guard, take out
the tip, soak in appropriate solvent & clean with a brush.
(Do not use a needle or sharp pointed instrument to clean
the tip. The tungsten carbide is brittle and can chip.)
GUN SAFETY LATCH
IN LOCKED POSITION
O-RING GASKET
REV-TIP™
METAL SEAT
GUN SAFETY
LATCH
RELEASED
REV-GUARD™
TO REMOVE CLOGS FROM SPRAY TIP
RETAINING NUT
REVERSE TO
UNPLUG
Spray Position Shown
CLOGGED FLAT TIP
AIRLESS SPRAY GUN
FIG. 11
1*
2*
3*
76
5
4
19
8
9
11
12
10*
13
14
15
16
PARTS LIST FIGURE 11
Item No. Part No. Description
1 120-530* Gun Seat Assembly
2 120-535* Gasket-Seat
3 120-520* Needle Assembly
4 120-529 Gun Seat Adapter
5 120-562 Trigger Guard
6 120-539 Pivot Trigger Pin
7 120-509 Gun Head
8 120-540 Actuator Pin (2)
9 120-536 Gun Plate
10 120-038* Nut
11 120-056 Plastic Washer
12 120-538 Gun Trigger Lock
13 120-055 Wave Washer
14 120-049 Retaining Ring
15 120-082 Handle Seal
16 120-090CX Gun Filter-Coarse
120-090FX Gun Filter-Fine
17 120-088 Spring
18 120-099 Gun Handle Assembly
19 120-506 Gun Trigger
* 120-534 Gun Repair Kit
17
18
11
13
AIRLESS SPRAY TROUBLESHOOTING
DEFECTS CAUSE CORRECTION
Coarse spray Low pressure Increase the pressure
Excessive fogging
(overspray)
Patten too wide Spray angle too large Use smaller spray angle tip
Pattern too narrow Spray angle too small use larger spray angle tip ( if coverage is OK, try tip in same
Too much material Nozzle too large
Too little material Nozzle too small Use next larger nozzle
thin distribution in center
of pattern “horns”
Thick skin of work Material too viscous
Coating fails to close &
smooth over
High pressure
Material too thin
Material too thin
Pressure too high
Worn tip
Wrong tip
Application too heavy
Material too viscous Thin cautiously
Reduce the pressure to satisfactory pattern distrabution
Use less thinner
nozzle group)
Use smaller nozzle
Reduce pressure
Material too thick
Change to new tip
Use nozzle with narrow spray angle
Thin cautiously
Reduce pressure and/or use tip in next smaller nozzle group
Spray pattern irregular,
deected
Craters or pock marks,
bubbles on work
Clogged screens Extraneous material in paint
Orice clogged
Tip damaged
Solvent balance Use 1 to 3% “short solvents remainder “long” solvents
Course pigments
Poorly milled pigments
(paint pigments glocculate)
Clean carefully
Replace with new tip
(this is most likely to happen with material of low viscosity,
lacquers, etc.)
Clean screen
Use coarse screen if orice size allows.
Use courser screen, larger orice tips. Obtain ball milled
paint. If thinner has been added, test to see if a cover
screen. Incompatible drop placed on top of paint mixes or
attens out on the paint mixture & thinners on the surface. If
not, try different thinner in fresh batch of paint.
TEST THE PATTERN
GOOD, FULL SPOTTY PATTERN, INCREASE PRESSURE
12
LINE STRIPING TIP CHART
NOTE: STRIPING TIPS SHOULD NOT BE USED FOR REGULAR SPRAYING.
REV-TIP™ for Striping, Part Number 562-xxxST
TIP IDENTIFICATION
• 1st 3-digits identies it as a REV-TIP™ for airless line striping (Part Number 562-xxxST).
• 4th digit is the fan width - the number is half the fan width, e.g., 2means a 4" line width.
• 5th and 6th digits are for the orice size and is measured in thousandths of an inch, e.g., 17 = 0.017 inch.
The higher the number, the larger the tip.
REVERSIBLE STRIPING TIP SIZE CHART
REV-TIPTM FOR STRIPING 562-XXXST
FAN WIDTH (6” FROM SURFACE) ORIFICE SIZE (INCHES)
INCHES MILLIMETERS .013 .015 .017 .019 .021
1-2 25-51 113ST 115ST 117ST
2-4 51-102 215ST 217ST 219ST 221ST
4-6 102-152 315ST 317ST 319ST 321ST
6-8 152-203 415ST 417ST 419ST 421ST
Striping paint Oil Base Oil Base Latex Latex Latex
REV-TIP™ protected By U.S. Patent No. 6,264,115. Other U.S. & foreign patents applied for.
TIP REPLACEMENT
During use, high pressure will cause the orice to grow larger. This destroys the pattern or will leave tailing or two heavy
lines on the outside of the pattern. REPLACE SPRAY TIP FREQUENTLY!
FIELD TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Unit doesn’t prime Airleak due to:
Unit primes but has poor
or no pressure
Unit does not maintain
good spraying pressure
•Loose suction nut
• Worn o-rings
•Hole in sucktion hose
Stuck or fouled balls
Pressure set too low
Filter(s) are clogged
Outlet valve fouled/worn
Prime/pressure relief valve
bypassing
Packings and/or piston worn
Blown spray tip
Packings and/or pistons worn
Upper seat worn
• tighten suction nut
• replace o-ring (106-011) on suction seat & o-ring (106-020)
below suction seat
• replace suction hose (331-290)
• service outlet valve suction assembly
• turn up pressure
• clean or replace gun lter, inlet lter, and/or manifold lter
• service outlet valve
• clean or replace prime valve
• tighten packing nut
• repack unit
• replace spray tip
• repack unit
• replace upper seat
13
SERVICING THE FLUID PUMP
FLUID PUMP DISCONNECT
REFER TO FIGURE 12
1. Follow the Pressure Relief Procedure on page 8.
2. Flush the material you are spraying out of the
machine.
3. Remove the connecting rod shield.
4. Move the piston rod to its lowest position by
cycling pump slowly.
5. Turn off the motor.
6. Disconnect sensor by holding it in place with a 7/8”
wrench and unscrewing the swivel with a 11/16”
wrench.
7. Remove the retaining ring from the connecting rod
and slide the sleeve down revealing the connecting
rod pin.
8. Remove the suction tube assembly from the uid
pump by unscrewing the suction nut with the packing
adjustment tool (189-211).
9. Using a 1/2” wrench unscrew the two bolts from
the cover assembly. The uid pump will be hanging
loosely at this point.
10.Remove the connecting rod pin out of the
connecting rod, allowing the removal of the uid
pump from the machine.
FIG. 12
13
FLUID PUMP REINSTALL
REFER TO FIGURES 12 & 14
1. Loosen the packing nut and ensure that the piston rod
is in its upper position in the uid pump body. Slip the
sleeve & the retaining ring over the piston rod.
2. Push the piston rod up into the connecting rod & align
the holes. Insert the connecting rod pin through the
connecting rod & piston. Slip the sleeve up over the
connecting rod pin and insert the retaining ring into the
groove on the connecting rod.
3. Push the two bolts through the tube spacers & screw
them into the cover assembly. Using a 1/2” wrench,
tighten the two bolts evenly (alternating between them)
until you reach 20 ft-lbs.
4. Reassemble lower suction valve assembly by placing
the suction seat, O-ring, suction ball & suction ball guide
in the suction nut & screw onto uid pump body.
5. Reconnect sensor to the uid pump body. Hold sensor
with a 7/8” wrench while tightening the swivel with a
11/16” wrench.
6. Start the machine and operate slowly to check the piston
rod for binding. Adjust the two bolts, holding the uid
pump body to the cover assembly, if necessary. This will
eliminate any binding.
7. Tighten packing nut clockwise until resistance is felt
against the Belleville Springs, go 3/4 of a turn more. Put
ve drops of Airlessco Throat Seal Oil in the packing nut.
8. Run the machine at full pressure for several minutes.
Release the pressure by following the Pressure Relief
Procedure & readjust the packing nut per step 7 above.
9. Install the connecting rod shield so that the
small hole is in the upper right hand corner.
12
1
11
2
10
9
8
14 15
3
4,5
6
7
Item No. Part No. Description
1 119-028 Connecting Rod Pin
2 331-117 Sleeve
3 331-062 Retaining Ring
4 115-019 Hose Connector
5 100-603 Swivel
6 331-034 Suction Nut
7 100-318 Bolts
8 331-209 Fluid Pump
9 331-093 Piston Rod
10 331-074 Tube Spacers
11 331-111 Connection Rod Shield
12 331-038 Connecting Rod
13 331-537 Cover Assembly
PARTS LIST FIGURE 12
SERVICING THE OUTLET VALVE
DISASSEMBLY OF THE OUTLET VALVE
1. Disconnect the Fluid Pump following instructions on
page 14.
2. Place piston holder in a vise. Slide piston into the holder
& lock in place with a 3/8” dowel.
3. Use a 1/4” allen wrench to unscrew the outlet seat
retainer from the piston.
4. Remove the outlet seat, O-ring and outlet ball.
5. Inspect outlet ball & seat for wear. Replace as
necessary. Ensure seat is right side up.
6. While piston is still locked in the holder, install parts back
into the piston in the following order:
BALL, OUTLET SEAT AND O-RING
Before reinstalling the outlet seat support, apply two
drops of Loctite No. 242 (blue) on the threads & torque to
20 ft-lbs.
NOTE: Airlessco LP pump tool kit 188-197 is required
for this task. Kit includes: Tightening Bar (189-211),
Packing Removal Tool (331-465), Piston Holder (331-
195), 3/8” dowel (331-196).
FIG. 13
1
2
3
1
4
5
6
7
SERVICING THE INLET ASSEMBLY
1. Un-thread and remove suction nut from the uid pump
body.
2. Remove suction seat, O-ring, suction ball and suction
retainer.
3. Clean all parts and inspect them for wear or damage,
replacing parts as needed.
4. Clean inside of the uid pump body.
5. Reassemble lower suction valve assembly by placing the
suction seat, O-ring, suction ball & suction ball guide in
the suction nut & screw onto uid pump body.
FIG. 14
8
9
10
11
Item No. Part No. Description
10 331-030 Suction Ball
11 106-011 O-Ring
12 331-409 Suction Seat
13 331-034 Suction Nut
PARTS LIST FIGURE 13 & 14
1 331-708 Piston
2 331-195 Piston Holder
3 331-196 Dowel Pin
4 331-027 Outlet Ball
5 331-100 O-Ring
6 331-026 Outlet Seat
7 331-314 Outlet Seat Retainer
8 331-011 Fluid Pump Body
9 331-029 Suction Ball Guide
12
13
15
17
PACKING REPLACEMENT PROCEDURES
DISASSEMBLY OF THE FLUID PUMP
REFER TO FIGURE 15 & 16
1. Discon nect the Fluid Pump as instructed on page 14.
2. Unscrew & remove the packing nut.
3. Push the piston rod down through the packings & out of
the pump.
4. Now push the packing removal tool up throughthe pump
& remove from the top bringing packings, spacer &
springs along with it, leaving uid body empty.
*Make sure all old packings & glands have been
removed from uid pump.
5. Clean inside of uid body.
6. Disassemble all parts & clean for reassembly. Discard
any old packings.
7. Lubricate leather packing in lightweight oil for 10 minutes
prior to reassembly.
REASSEMBLY
REFER TO FIGURE 15
1. Take lower male gland & place it down on the
at side.
2. Take three of the lower polyethylene packings & two of
the leather packings & place onto the male gland inthe
following order with the inverted side down
POLYETHYLENE, LEATHER, POLYETHYLENE,
LEATHER, POLYETHYLENE.
3. Take the female adaptor, which is inverted on both sides
, & place it on top of your assembled lower packings.
4. Follow step 2 with your packings inverted side up.
5. Take the second lower male gland and place it on top
of your assembled packings with the rounded side
down.
6. Take assembled glands & packings (13 pieces) & slide
onto the lower half of the piston.
7. Take the spacer & slide over the top of the piston (it
doesn’t matter which direction it sits, falling onto lower
packings.
8. Take three Belleville Springs & slide over the top of the
piston in the following order:
• First spring, curve facing down
• Second spring, curve facing up
• Third spring, curve facing down
9. Take the upper male gland & place it rounded
side up.
10. Take three upper polyethylene packings & two leather
packings & assemble with inverted side down, on
to the male gland in the following order: polyethylene,
leather, polyethylene, leather, polyethylene.
11. Take upper female gland & place on top of assembled
upper packings with the inverted side down.
12. Take assembled upper glands & packings (7 pieces) &
slide on over the top of the piston, making sure inverted
sides are down.
( (
(
13. Take the packing holder & replace the white O-ring &
the black O-ring with new ones from the packing kit.
14. Slide the packing holder over the top of the upper
packings so they t inside.
15. Lubricate inside of the uid pump body & the outside of
the packings with a light weight oil.
16. Slide assembly into uid pump body.
TO KEEP PACKINGS SECURED IN CORRECT
POSITION, HOLD THE PUMP BODY UPSIDE DOWN
& PUSH THE COMPLETED ASSEMBLY UPWARDS
INTO THE PUMP BODY. ONCE PLACED INSIDE, TILT
PUMP BODY BACK UP TO KEEP ALL PIECES IN.
17. Tighten packing nut onto the top of the uid pump
body & tighten until you feel slight resistance against the
Belleville Springs. Using the Packing Adjustment Tool,
tighten another 3/4 of a turn.
!8. Reinstall Fluid Pump as instructed on page 14.
FIG. 15
21
20
19
18
17
16
15
14
13
11
12
10
PARTS LIST ON FOLLOWING PAGE
1
2
23
22
3
2
1
4
5
6
7
8
9
16
PACKING REPLACEMENT PROCEDURES
FIG. 16
2*
19*
18*
25*
24*
1*
22*
17*
20
16*
15*
14
21
4
13*
11
3*
23*
1*
PARTS LIST FIGURE 15 & 16
Item No. Part No. Description
1 331-014* Male Gland
2 331-016* Packing Polyethylene
3 331-308* Female Adaptor
4 331-011 Fluid Pump Body
5 331-029 Suction Ball Guide
6 331-030* Suction Ball
7 106-011* O-Ring
8 331-409 Suction Seat
9 331-034 Suction Nut
10 331-314 Outlet Seat Retainer
11 331-026 Outlet Seat
12 331-100* O-Ring
13 331-027* Outlet Ball
12*
7*
6*
PARTS LIST FIGURE 15 & 16 CONT
Item No. Part No. Description
14 331-708 Piston
15 331-018* Spacer
16 331-025* Belleville Springs
17 331-022* Male Gland
18 331-023* Packing Polyethylene
19 331-021* Female Gland
20 331-019 Packing Holder
21 331-037 Packing Nut
22 331-307* Packing Leather
23 331-306* Packnig Leather
24 106-009* White O-Ring
25 106-010* Black O-Ring
* 331-210 Packing Kit
5
17
19
GEARBOX (305-341)
FIG. 17
10 11 2 1
6 7 8 9 7
3 4 5
1 2
25
26
35
34
33
27
28
12 13 14 15
16171819
2021222324
29303132
PARTS LIST FIGURE 17
Item No. Part No. Description
1 100-380 Shoulder Screw (2)
2 100-381 Screw (2)
3 331-537 Cover
4 331-046 Ball Bearing
5 331-038 Crosshead Assy
6 331-408 Crank Assy
7 113-093 Retaining Ring (3)
8 112-068 Ball Bearing
9 305-340 Pinion Shaft
10 305-047 Ball Bearing
11 305-287 End Bell
12 305-342 Mounting Box Bracket
13 100-374 Screw (4)
14 301-666 Clutch Assy
15 112-029 Key
16
17 331-496 Set Screw (4)
18 113-023 Washer
301-160
175-032
Motor Honda GX160
Motor Duro 5.5HP (SS3650/FS D)
(SS400/ FS +)
PARTS LIST FIGURE 17 CONT
Item No. Part No. Description
19 331-497 Nut (4)
20 100-398 Retaining Ring
21 136-217 Nut (2)
22 188-041 Screw(2)
23 117-008 Bearing
24 113-094 Key
25 119-028 Pin
26 331-117 Sleeve
27 331-062 Retaining Spring
28 331-209 Fluid Pump
29 115-019 Hose Connector
30 331-074 Spacer (2)
31 331-061 Sleeve Bearing
32 100-318 Scre (2)
33 331-197 Screw (2)
34 331-103 Washer (2)
35 331-111 Cover Guard
* 331-132 Grease (116)
18
CLUTCH ASSEMBLY
FIG. 18
1, 2, 3 104
19, 20
18
5, 6
7*, 8*, 9*
11*, 1213, 14, 15*, 161721
PARTS LIST FIGURE 18
Item No. Part No. Description
1 331-496 Screw
2 331-497 Nut
3 113-023 Lock Washer
4 175-032 Motor Duro 4.0HP
5 111-016 Nylon Tie
6 100-637 Mounting Base
7 100-632* Locknut
8 100-633* Screw
9 100-634* Lock Washer
10 112-029 Key
11 305-279* Clutch Adapter
PARTS LIST FIGURE 18 CONT
Item No. Part No. Description
12 331-495 Bushing
13 113-093 Retaining Ring
14 113-094 Key
15 305-278* Clutch
16 331-178 Rubber Extrusion
17 100-374 Screw
18 305-342 Mounting Box Bracket
19 136-217 Nut
20 188-041 Screw
21 305-310 Gearbox and Pump Assy
* 301-666 Clutch Assy
21
FRAME ASSEMBLY (305-411)
FIG. 19
SEE PAGE 21
27 28 29 30
34 35
31, 32, 33
1, 2, 3, 4
5
6
7, 8, 9, 10
11, 12, 13, 14
15, 16
11, 12, 13, 17
18
26
PARTS LIST FIGURE 19
Item No. Part No. Description
1 136-023 Cable End Lug
2 301-335 Shrink Tubing (2)
3 305-089 Cable Insert
4 305-105 Lever
5 305-058 Rubber Grip (2)
6 305-314 Handle Weldment (Left)
7 113-022 Nut (2)
8 100-686 Paint Hose Hook (4)
9 100-344 Washer (4)
10 100-360 Screw (4)
11 100-696 Nut (2)
12 140-034 Washer (2)
13 140-035 Washer (2)
14 100-695 Screw (2)
15 100-687 Two Channel Strap (3)
16 100-688 Screw (3)
17 139-327 Rivnut (2)
18 301-166 13” Wheel
19, 20, 21, 22, 23, 24, 25
PARTS LIST FIGURE 19 CONT
Item No. Part No. Description
19 188-367 Axle
20 100-369 Wave Washer (2)
21 113-030 Spacer (2)
22 136-131 Chain Sash
23 136-133 Key Ring
24 143-029 Set Collar (2)
25 143-028 Washer (2)
26 305-395 Frame
27 305-396 Bucket Base
28 119-026 Screw (3)
29 305-428 Stop
30 100-621 Cap
31 188-042 Lock Nut (4)
32 305-185 Brake Clamp
33 100-390 Screw (4)
34 100-601 Plug (2)
35 305-315 Handle Weldment (Right)
20
SWIVEL WHEEL ASSEMBLY
FIG. 20
12*
15
14
13
11
10
16
17
9
19
20
21
22
18
8
7
6
5
4
23 24
27
23
28
29
10
25, 26
2
1
PARTS LIST FIGURE 20
Item No. Part No. Description
1 143-029 Set Collar (2)
2 143-028 Washer (4)
3 136-230 Axel
4 305-253 Swivel Clamp
5 139-337A Wheel
6 305-257 Swivlel Lock Pin
7 305-258 Swivel Lock
8 136-223 Spring
9 100-223 Grease Fitting
10 119-035 Nut (4)
11 100-344 Washer (2)
*12 305-395 Frame Weldment
13 179-029 Spacer (2)
14 100-648 Screw (2)
15 305-261 Cabel Holder
3
1
2
* The swivel wheel weldment is part
of the entire striper frame weldment.
PARTS LIST FIGURE 20 CONT
Item No. Part No. Description
16 100-652 Cable
17 305-259 Lock End Lug
18 305-141 Cable Adjustor
19 100-318 Screw (2)
20 113-023 Washer (2)
21 113-021 Cotter Pin
22 260-029 Hex Castle Nut
23 112-008 Flanged Bearing (2)
24 111-036 Spring Clamp
25 140-040 Washer (2)
26 117-072 Screw (2)
27 136-231 Turnbuckle
28 140-053 Washer
29 100-649 Screw (2)
GUN ASSEMBLY (305-167)
FIG. 21
1
6
7
Item No. Part No. Description
1 305-150 Gun Holder
2 561-002 RevGuard (G Thread)
3* 561-025 Seal-Metal
5
4
3
2
4* 561-026 Seal-Plastic
5 032-028 Swivel Assembly
6 120-554 008 Airless Gun
7 100-177 Elbow
* 561-029 Seal Kit
PARTS LIST FIGURE 21
GUN HOLDER ASSEMBLY (305 - 150)
FIG. 22
8
11
9
Item No. Part No. Description
1 305-142 Lever Assy.
2 305-089 Cable Insert (2)
1
3
8
26
2
25
4
5
6
7
12
15
14
13
10
24
23
22
21
20
19
18
17
16
3 100-685 Gun Cable Assy.
4 305-141 Cable Adjuster
5 111-052 Tube Connecter
6 305-154 Bracket
7 305-152 Clamp (2)
8 305-157 Knob (3)
9 100-342 Screw
10 305-159 Sleeve Bearing (2)
11 140-045 Jam Nut (2)
12 305-161 Spacer (2)
13 305-079 Wire Swivel Assy.
14 305-155 Lever
15 140-051 Nut
16 116-100 Spring
17 169-050 Screw
18 113-027 Lock Washer
19 305-156 Thrust Washer (2)
20 305-158 Shoulder Screw
21 100-673 Screw
22 305-297 GS Holder
23 116-105 Spring Clip
24 143-027 Ball Guide
25 171-008 Screw (2)
26 136-019P Swivel Clam Assy.
PARTS LIST FIGURE 22
22 23
PAINT SYSTEM
FIG. 23
1
5 6
2
3
4
7 8
9
10
15
PARTS LIST FIGURE 23
Item No. Part No. Description
1 120-554 008 Airless Gun
2 100-011 Hose 50’ x 1/4”
3 100-109 Nipple 3/8” x 1/4”
4 100-199 Hose 6’ x 3/8”
5 115-019 Connector
6 100-226 Elbow 45º
7 331-209 Fluid Pump
8 100-603 Swivel
11
121314
PARTS LIST FIGURE 23 CONT
Item No. Part No. Description
9 331-294-99 Sensor
10 100-180 Prime Valve
11 100-660 Elbow 1/8” x 1/4”
12 100-012 Hose 4’ x 1/4”
13 188-373 Return Pipe
14 305-293 Reector
15 100-642 Gasket
23
SUCTION ASSEMBLY (331-238)
FIG. 24
7
9
10
1
5
6
82
4
3
PARTS LIST FIGURE 24
Item No. Part No. Description
1 331-290 Suction Hose Assy
2 331-217 Inlet Strainer
3 331-035 Suction Elbow
4 331-034 Suction Nut
5 106-020
24 25
PTFE O-Ring
Item No. Part No. Description
PARTS LIST FIGURE 24 CONT
6 331-231 Bypass Hose Assy
7 331-425 Bypass Hose
8 331-090R Fitting
9 111-016 Nylon Tie
10 331-135 Spring Clip
DUAL WHEEL FLOATING GUN ASS’Y - FS D/+
FIG. 25
28, 29, 30
27
26
25
24
23
18
17
13, 14, 15, 16
31 28, 32, 33, 34 36
6
19 20, 213522
7
8
9
10
11
1
2
3
4
5
PARTS LIST FIGURE 25
Item No. Part No. Description
1 305-352 Mounting Tube
2 305-367 Wheel (2)
3 143-029 Set Collar (4)
4 305-351 Axel
5 305-079 Wire Swivel Assy.
6 119-049R Screw
7 305-273 Spacer (2)
8 305-089 Cable Sleeve
9 305-141 Cable Adjustor
10 116-100 Compression Spring
11 331-103 Washer (3)
12 136-217 Nylon Lock Nut
13 100-342 Screw, 5/16
14 305-161 Spacer
15 305-159 Sleeve Bearing (2)
16 140-045 Nut
17 305-274 Trigger Lever
18 305-243 Gun Holder Tube
19 119-276 Spring Clip
12
PARTS LIST FIGURE 25 CONT
Item No. Part No. Description
20 119-052 Lock Nut (2)
21 305-050R Screw (2)
22 305-077 Cable Assy.
23 305-108 Clamp Plate (2)
24 305-051M Clamp (2)
25 100-320 Wing Screw (2)
26 305-292 Support Tube (2)
27 136-019P Swivel Block (3)
28 140-051 Nut (4)
29 140-035 Lock Washer (3)
30 188-125 Screw, 3/8 HX (3)
31 136-039R Set Collar
32 136-039 Set Collar
33 171-088 Screw 3/8 (4)
34 188-378 Spacer
35 143-027 Ball Guide (5)
36 305-157 Knob - SG Holder Assy.
37 305-142 Hand Lever (Not Shown)
25
27
REPLACEMENT OF ELECTRICAL CONTROL BOARD
1. Remove electrical cover.
2. Disconnect sensor lead from Electrical Board.
3. Disconnect two clutch leads on Electrical Board from
leads on clutch.
4. Using a 1/16" allen, loosen set screw in Pressure Control
Knob and remove knob.
5. Using a 1/2" nutdriver or 1/2" deep socket, remove nut
from pressure control shaft. This will allow removal of
electrical control board from frame.
6. Replace Electrical Board Assembly in reverse order.
Adjust pressure as per procedure below, "Pressure
Calibration on the Electrical Control Board".
PRESSURE CALIBRATION OF THE ELECTRICAL CONTROL BOARD
1. Turn "Pressure Calibration" Trimpot adjustment on
electrical control board in the counter clockwise direction
at least 15 revolutions.
2. Connect 5000 psi glycerine pressure guage on outlet of
pump between uid pump & airless hose to monitor Fluid
Pump Pressure.
3. Start engine and run at maximum RPM. Turn Prime
Valve to the open (Prime) position. Turn Pressure
Control Knob to maximum position (fully clockwise).
SENSOR
FIG. 26
PRESSURE
CALIBRATION
4
BLACK
3
TRIMPOT
4. Using an insulated screwdriver, adjust "Pressure
Calibration" Trimpot by turning clockwise until the
clutch engages. When the clutch engages the pump
will commence Priming. When pump is primed, turn
the Prime Valve to the Closed (Pressure) Position.
THE PUMP WILL BEGIN TO PRESSURIZE AND THE
CLUTCH WILL DISENGAGE AT A LOW PRESSURE.
CONTINUE TURNING THE TRIMPOT CLOCKWISE
TO INCREASE PRESSURE TO 3000 PSI.
5. Trigger gun. The pressure should drop approximately
350-400 psi, the clutch will engage and build
pressure to 3000 psi and disengage. Trigger gun
several times to ensure proper pressure setting.
6. Turn Pressure Control Knob to minimum position.
The clutch should disengage and pump stop moving.
7. Secure leads with tie strap.
8. Replace cover on unit. Ensure the leads are not
pinched or damaged in the process of replacing
covers.
BLACK
GREEN
TO ENGINE
PARTS LIST FIGURE 26
Item No. Part No. Description
1 106-019 O-Ring
2 301-523A Knob
3 117-045 Grommet
4 301-282-99 Control Board
26
BLUE
BLUE
1
2
BLACK
BLACK
TO CLUTCH
(301-666)
ELECTRICAL TROUBLESHOOTING - Clutch Does Not Engage
STEP 1: Ensure that the pressure control knob (POT) is in the maximum (CW) position.
STEP 2: Remove the clutch and electrical box covers.
STEP 3: Check all electrical connections between the engine magneto, sensor, control board and clutch for loose
connections or damaged leads.
STEP 4: Disconnect the two leads from the control board (blue) and the clutch assembly (black). Using a multimeter,
with the engine at maximum RPM, pressure control knob in the maximum position and the prime valve open (priming)
position, test the DC voltage across the boards leads (blue). This voltage must be 13-14 VDC. If the readings are correct,
the board, sensor and magneto are okay and the problem is the clutch assembly. If this is the case, proceed to Step 5. If
the voltage is outside this range go to Step 7.
STEP 5: Check the spacing between the clutch eld and plate. The gap should be a maximum of .010”. If the gap is
greater than .010” the gap is too wide. If this gap is too wide, replace the clutch assembly.
STEP 6: When the DC voltage from the board is not 13-14 VDC, disconnect the control board lead (black) from the
engine magneto lead (pink), located on the side of the engine. With the engine at maximum RPM (3600), pressure control
knob in maximum (CW) position and prime valve open (priming), read the AC voltage from the magneto lead to the
sprayer frame. This reading should be 19-24 VAC. If outside this range, contact your local small engine repair facility for
magneto replacement. If the magneto is producing the proper AC voltage, continue to Step 7.
STEP 7: Test the sensor by reading the resistance between the red and black wires. The resistance runs between 1.5-3K
ohms. A defective sensor usually shows no resistance (open). If the reading is outside standards, replace the sensor. An
alternative method to test the sensor, is to plug a new sensor into the board and see if the clutch will engage. Caution!
When using this method, ensure prime/pressure valve is in the prime position. This is important because the sensor
plugged into the board is not measuring pressure in the uid section.
STEP 8: When Steps 6 & 7 have been completed and the magneto and sensor check good, the electrical control board is
the only item left, replace the board.
27
29
NOTES
28
STRIPING ACCESSORIES
STENCIL KIT
For use on any single gun
striper for stencilling or
spraying paint. Includes a
2nd gun, 50’ of ” airless
hose, 18” extension pole
& shut-off ball valve.
PART # 305-399
FLOATING SPRAY GUN KIT
Upgrades any Airlessco
striper to a oating gun
mount for consistent width
lines on bumpy, uneven
surfaces like sports elds.
Wheels provide added
wind protection for spray
pattern.
PART # 305-355. (PATENT PENDING)
12GAL CONTAINER
High capacity plastic paint
bucket
PART # 189-006
POINTER
For easy line-up and
striping of long lines.
PART # 136-069
BEAD DISPENSERS
Gravity type glass bead
dispenser kits.
1 GUN 4” PN 305-174
1 GUN 4-6” PN 305-186
29
Quick Flush
Quick Flush
■ The only clean water
■ Cuts sprayer clean-up time in half!
■ Connects to standard garden hose
to backush sprayer through gun
■ Includes "F" and "G" adapters to
work with all brands of gun
Part # 170-005
ushing system
PAINT HOPPER
For use on small jobs where paint is
kept in smaller than 5 gallon containers.
Threads onto pick-up tube of carry or
LoBoy framed Airlessco sprayers.
331-775 6 Liter Paint Hopper
™
Spray protectant for machine
to prevent paint from sticking
to it. Keeps your sprayer
looking new for years!
Case quantity: 12 cans
STAY CLEAN
114-030
20 oz. can
THROAT SEAL OIL
Used in the wet cup of a piston pump
to prevent paint from drying on the piston & causing damage to the upper
packing. Use with all piston pumps.
188-187 6 oz. Bottle
188-392 1 qt. Bottle
XTEND-A-POLE SYSTEM
PUMP CONDITIONER
Should be used on piston pumps
between uses to prevent paint from
drying on the piston & causing packing wear.
010-001 Display of 48 - 1 oz. bottles
010-009 1 quart bottle
010-019 1 Gallon bottle
Case quantity: 12 on quarts, 4 on gallons
Pre-filter your paint using strainer
bags. One dozen per pack.
ACCESSORIES
4 mil poly protects your
airless hose from paint and
abrasion damage. Comes in 1000'
roll with perforations each 50'.
100-426 Case of 6 Rolls
PAINT STRAINERS
100-064 Used to cover suction filter
100-065 5 Gallon strainer
HOSE COVER
100-219 Hose Cover Roll
STANDARD TIP EXTENSION, “G” Thread
032-170 6” Long
032-171 12” Long
032-172 18” Long
032-173 24” Long
SWIVEL EXTENSION, “G” Thread
032-184 36” Long
BARE POLE
Add Tip Extension or Swivel Extension to
create desired length
032-053 24” Long
032-054 36” Long
032-035-55 7/8" x 14 Swivel
HIGH PRESSURE AIRLESS HOSE
Strong yet flexible, for airless sprayers up to 3300 PSI
Part No: Hose Description
100-012 3/16” Whip Hose, 4 Ft.
100-040 1/4” Whip Hose, 3 Ft.
100-204 1/4” Whip Hose, 5 Ft.
100-199 3/8” Whip Hose, 6 Ft.
100-011 1/4” Hose, 50 Ft.
100-023 3/8” Hose, 50 Ft.
100-037 1/2” Hose, 50 Ft.
100-010 1/4" Hose Connector
100-009 3/8" Hose Connector
Standard Tip Extension
Swivel Extension
Bare Pole
SWIVEL “G” THREAD
ADAPTERS
90° Pole to Gun Adapter
032-042
Gun Nut “F” Thread 11/16-16
032-010
Gun Nut “G” Thread 7/8-14
032-011
"F to G" Gun adapter to attach
®
Graco
tips to Airlessco guns.
032-012
AIRLESSCO
™
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